US 11,434,136 B2 · Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Abstract

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 μm) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 μm). During high pressure-high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

Claims19

Dependent claims

A feedstock for manufacturing a polycrystalline diamond body, the feedstock comprising:

a plurality of diamond particles including at least one fraction of modified diamond particles having a first median particle distribution D50 and at least one fraction of monocrystalline diamond particles having a second median particle distribution D50;
wherein the first median particle distribution D50 is less than the second median particle distribution D50, and
wherein at least about 40% of the first fraction of modified diamond grains have a sphericity of less than about 0.7 and at least about 75% of the second fraction of monocrystalline diamond grains have a sphericity of greater than about 0.8.

Dependencies are inferred from the claim text.

Facts

Application

16/806,152Filed 2 Mar 2020 · continuation

Priority

30 Mar 2015

Published

US 2020/0198978 A125 Jun 2020

Granted

6 Sep 2022

Term ends

Not estimatedThe source records don’t support an estimate.

Classification27 codes

C01B 32/25
Carbon; Compounds thereof: diamond
B24D 3/008
Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their…:…
B24D 18/0009
Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for: using moulds or presses
C01B 32/26
Diamond: preparation

Family

Application62/139,819Us provisional application · filed 30 Mar 2015

Application15/074,092Parent of this division · filed 18 Mar 2016

Application15/948,158Parent of this continuation · filed 9 Apr 2018

US 10,017,390 B2Parent of this division · filed 10 Jul 2018

US 2020/0198978 A1Pre-grant publication · published 25 Jun 2020

US 10,618,814 B2Parent of this continuation

Application15/948,158Parent of this division

US 2016/0289078 A1Published application

US 2019/0106327 A1Published application

US 11,434,136 B2This patent

From the US filing history. Foreign family members aren’t listed.

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Life of this patent

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Life of this patent

Abstract

Claims19